Method and system for palletizing peat moss

ABSTRACT

A system for palletizing peat moss in bulk form, comprising a dosing and feeding unit; a filling and compaction unit, receiving an amount of peat moss determined by the dosing and feeding unit, and compressing each determined amount of peat moss into a compressed bloc of peat moss on a pallet; a stabilization unit, receiving, from the filling and compaction unit, pallets, each pallet supporting a compressed bloc of peat moss, and wrapping the compressed bloc for stabilization thereof; a weighing and height measuring unit, measuring each compressed bloc received from the stabilization unit; and a wrapping unit, finally wrapping each measured compressed bloc.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims benefit, under 35 U.S.C. §119(e), of U.S.provisional application Ser. No. 61/555,715, filed on Nov. 4, 2011. Alldocuments above are incorporated herein in their entirety by reference.

FIELD OF THE INVENTION

The present invention relates to improvements in the field of peat mossbulk shipping. More particularly, the invention pertains to a method andapparatus for palletizing peat moss in bulk compressed form.

SUMMARY OF THE INVENTION

More specifically, in accordance with the present invention, there isprovided a system for palletizing peat moss in bulk form, comprising adosing and feeding unit; a filling and compaction unit, receiving anamount of peat moss determined by the dosing and feeding unit, andcompressing each determined amount of peat moss into a compressed blocof peat moss on a pallet; a stabilization unit, receiving, from thefilling and compaction unit, pallets, each pallet supporting acompressed bloc of peat moss, and wrapping the compressed bloc forstabilization thereof; a weighing and height measuring unit, measuringeach compressed bloc received from the stabilization unit; and awrapping unit, finally wrapping each measured compressed bloc.

There is further provided a method for palletizing peat moss in bulkform, comprising a) determining an amount of peat moss corresponding toa target bloc; b) feeding the determined amount to a compaction box andcompacting into a compacted bloc supported by a pallet; c) stabilizingthe compacted bloc; d) measuring the compacted bloc; and e) wrapping thepallet with the compacted bloc thereon.

Other objects, advantages and features of the present invention willbecome more apparent upon reading of the following non-restrictivedescription of specific embodiments thereof, given by way of exampleonly with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the appended drawings:

FIG. 1 a is a schematical perspective view; FIG. 1 b is a schematicaltop view; and FIG. 1 c is a schematical side view; of a system accordingto an embodiment of an aspect of the present invention;

FIG. 2 a is a schematical view of a doser in the system of FIG. 1, andFIG. 2 b is a detail of FIG. 2 a;

FIG. 3 is a schematical view of a sampler in the system of FIG. 1;

FIG. 4 a is a first perspective schematical view; FIG. 4 b is a sideschematical view; and FIG. 4 c is a second perspective schematical view,of a compaction box according to an embodiment of an aspect of thepresent invention;

FIGS. 5 a and 5 b—show details of FIG. 4 a;

FIG. 6 shows details of FIG. 4 a;

FIG. 7 a) is a perspective partial schematical view and b) is a topview, of a compaction box according to an embodiment of an aspect of thepresent invention;

FIG. 8 shows a conveyer according to an embodiment of an aspect of thepresent invention;

FIG. 9 show a pallet feeder a) in down and b) up positions according toan embodiment of an aspect of the present invention;

FIG. 10 show a) a top view of a compaction box according to anembodiment of an aspect of the present invention b) a top view of a ventin a wall of the compaction box according to an embodiment of an aspectof the present invention and c) a perspective view of a palletized blocaccording to an embodiment of an aspect of the present invention;

FIG. 11 is a) a side view and b) a top view of units of the system ofFIG. 1; and

FIG. 12 is a block diagram schematically illustrating a method ofpalletizing peat moss according to an embodiment of an object of thepresent invention.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

As illustrated for example in FIG. 1, a system according to anembodiment of an aspect of the present invention comprises a dosing andfeeding unit 12, a filling and compaction unit 14, a stabilization unit16, a weighing and height measuring unit 18, a wrapping unit 20 and anoutput unit 22.

The illustrated dosing and feeding unit 12 comprises two feeding lines(I) and (II), each line comprising a doser 30 (FIG. 1 a).

The doser 30 is essentially a supply of peat moss, fed with peat mossfrom the back. As illustrated in FIG. 2 a, a doser 30 comprises aconveyor 310 and an equalizer 320, the equalizer 320 pushing thematerial towards the front (see arrow A in FIG. 2 a). The equalizer 320comprises rotating aluminum bats 322 that gradually push the materialforwards, ensuring constancy in volumes by using a number of sensorspositioned at intervals, each one corresponding to a predeterminedvolume, and monitored through a panel view 330 (see FIG. 2 b). Thevolumes are thus automatically selected, without manual manpower, byselecting a sensor from the panel view 330. Filling of the doser,equalizing and dumping from the doser, at the front end of the doser 30,into the compaction box of the filling and compaction unit 14 are allcontrolled by an automate (PLC) and fully automatic.

As best seen in FIG. 3, a sampler 324 is provided at the back of thedoser 30, for collecting a reference volume, i.e. a cubic foot box forexample, of material of each amount determined by the doser 30. A cubicfoot box (12 in×12 in×12 in) is fed by a sampler screw 325 in a cubicbox (not shown), and the weight of the cubic foot is measured by the PLCand stored as a reference. The cubic box is then emptied for a nextsampling and measurement. This is done twice for each amount determinedby the doser 30 for a given bloc of predetermined volume, for example240 cubic foot, since it is found that an average over two referencemeasurements provides a reasonable accuracy for the bloc. This samplingis controlled by a programmable logic controller (PLC) and fullyautomatic. Another sampler (not shown) may be provided to collectmaterial sampling, for humidity content testing for example.

The doser 30 thus determines the amount of material to be fed into thecompaction box 40 of the filling and compaction unit 14 for a specificbloc.

As people in the art will appreciate, in the present system, the volumesare determined upstream of the filling and compaction unit 14. Moreover,by providing two feeding lines (I) and (II), as best seen in FIG. 1 a,typically one feeding line for coarse peat moss and one feeding line forfine peat moss, the system allows production of two different products,using the same wrapping units, by allowing compaction of a bloc of afirst type, for example coarse peat moss, at the filling and compactionunit 14 while wrapping of a bloc of a second type, for example fine peatmoss, at the wrapping units, in a continuous process. As a result, thespeed and production rate are increased since different types andqualities of peat moss can be processed concurrently with the samesystem.

The amount of peat moss determined by the doser 30 is dumped from thefront end of the doser 30 into the compaction box 40 of the filling andcompaction unit 14, positioned below the dosing and feeding unit 12 inFIG. 1 a. This discharge of the material at the front of the doser 30into the compaction box takes barely 12 to 15 sec. Thus, the compactionbox 40 receives the amount of material as determined in the doser 30 fora bloc, as described hereinabove.

As shown in FIG. 4, the compaction box 40 comprises a top part 510 and amobile bottom part 520. A flange 530, i.e. a ring part, mobile on railsand bearings and hydraulically driven for example, is adapted to belifted from the bottom part 520 to disengage the bottom part 520 fromthe top part 510 to allow the bottom part with a compacted bloc thereinto leave the filling and compaction unit 14 for the stabilization unit16, and to engage the bottom part 520 for connection with the top part510 at the filling and compaction unit 14 for receiving the peat mossfrom the doser 30 for compaction. When the bottom part 520 is below thetop part 510 for receiving the peat moss from the doser, the flange 530in position therebetween ensures continuity between the two parts,thereby preventing dust or material leaks between the two parts 510 and520. Those actions are monitored by the PLC and are all automatic. InFIG. 7, the bottom part 520 of the compaction box 40 is shown with itsdoors open.

As shown in FIGS. 4 and 5, the bottom part 520 is mobile on tracks 540provided below the box 40, which allows saving space above the box 40. Afirst track 540 a may have a V shape so as to guide the box 40 andensure it does not move sideways and a second track 540 b may beprovided with a flat wheel to give a sideways play to the box 40,thereby avoiding that the box 40 gets jammed on the tracks.

As shown in FIGS. 4 c, 5 and 6, the filling and compaction unit 14comprises a pallet feeder 570 comprising arms 550 and a frame 560, whichhandles a bundle of pallets and deposits one pallet at a time at theback of the box 40. In FIGS. 4 c, 5 b or 6, a pallet (P) is shown,waiting to be deposited behind the compaction box 40 on the tracks 540by opening of the arms 550 so that the frame 560 moves down. When thebottom part 520 of the compaction box 40 is back at the filling andcompaction unit 14 from the stabilization unit 16, the pallet feeder 570thus deposits a pallet behind the box and slides the pallet inside thebox for receiving a next load of material. The frame 560 can move up anddown to lift the bundle of pallets as shown in FIG. 5 b. In previoussystems, the pallets had to be manually positioned, which was dangerousand, although efficient for a production of 10 blocs/hour, could notallow a production of up to 32 blocs/hour. In the present system, thepallet feeder 570 is provided at the back of the machine, with hydraulicarms 550 that take pallet bundles to leave only one pallet on theconveyor 310, just behind the compaction box 40. It is a two actionsystem: open/close arm 550 on the pallet bundle and up/down the palletbundle. As a result, a pallet is left behind the box 40 when the bottompart 520 of the compaction box 40 leaves a compressed bloc at thestabilization unit. When the bottom part 520 of the compaction box 40returns to the filling and compaction unit 14, the pallet enters in thebox 40 by an opening of the size of the pallet in the bottom part 520.All those actions are monitored by the PLC and fully automatic.

The filling and compaction unit 14 comprises a piston and cylinderarrangement 15, supported by a frame 17 (best seen in FIG. 1 c), forcompaction of the amount of peat moss determined by the doser, withinthe compaction box 40. A digital encoder is used to monitor the courseof the piston so as to control the compaction ratio and the height ofthe bloc formed. The height of the bloc is thus precisely andautomatically controlled, and uniform. The peat moss is compressed at apressure between 3 and 5 kg/cm², for example at about 3.85 kg/cm², to avolume ratio of non-compressed peat moss to compressed peat moss between2:1 and 3:1.

The compaction box 40 may be provided with vents (see for example FIGS.4 a, 4 b, 4 c, 7 a), allowing air expulsion during compaction. In orderto prevent such vents from being obstructed by the peat moss, the ventsare formed by tapered bores in the doors of the compaction box 40, asshown in FIG. 10 b for example, the tapering resulting in any materialentering the bores to slide on the tapered surfaces of the bores,without obstructing them.

As shown in FIG. 10 a, the compaction box 40 is provided with innerround corners 600, so as to produce peat blocs 700, shown in FIG. 10 bon a pallet (P) for example, having round corners 710, which are foundto be more resistant to breaking. Back inner corners 600 b of thecompaction box 40 may have an angle of 90 degrees, and the front innercorners 600 a of the compaction box 40 may have an angle of 92 degrees,thereby reducing the risks that the bloc corners break upon opening ofthe front doors of the box.

FIG. 8 shows a conveyor, driven by a motor 546, and the tracks 540 thatguide the mobile part of the compaction box 40 from the filling andcompaction unit 14 to the stabilization unit 16. Forks 542, actuated bycylinders 544 for example, support the pallet during compression of thepeat moss within the compaction box 40, at the filling and compactionunit 14.

At the stabilization unit 16, a top platen 311, best seen in FIG. 11 a,driven by a piston for example, is moved to contact the top surface ofthe bloc upon arrival of the bottom part 520 of the compaction box 40,thereby stabilizing the bloc, before the doors of the bottom part 520open to release the bloc. The bottom part 520 of the compaction box 40leaves the pallet with the bloc thereon and withdraws to the filling andcompaction unit 14. An elevator 548, actuated by a cylinder 541 forexample, is used to lift the pallet (P), placed on a plate 543 (seeFIGS. 8 and 9), and a layer of film is wrapped about the loaded palletfor stabilization of its expansion, as fast as possible, i.e. withinbetween 45 to 60 s from its output from the compaction box 40, so thatthe bloc remains straight and integral, i.e. so that the bloc does notcollapse, the conveyer remaining in position, as best seen in FIG. 9.

As shown in FIG. 11, the stabilization unit 16 may comprise a rotary armstretch wrapper. The wrapper needs not be mobile or moved away to allowthe box 40 to deliver the bloc, since the tracks 540 allow moving thecompaction box 40 with the loaded pallet forward, as mentionedhereinabove. Those entire steps are fully automated by the PLC and needno manpower.

From the stabilization unit 16, once stabilized as describedhereinabove, the bloc is moved to a scale and a linear resistance at theweighing and height measuring unit 18, to have its height and weightmeasured. These pieces of data are processed in a PC with the weight ofthe reference volume as determined before by sampling at the dosing andfeeding unit 12 as described hereinabove so as to confirm the volume ofthe bloc, and an identifying sticker is generated for that bloc. Allthose steps are completely automated. The identifying sticker typicallyindicates the time of production of the bloc, the kind (coarse/fine) ofthe product, the weight, the volume, the height of the bloc, the weightof the reference volume. The sticker is printed with a unique ITN # andis put it on the bloc itself. Simultaneously, quality tests may beperformed on the bloc.

The wrapping station 20 is provided after the weighing and heightmeasuring unit 18. In FIG. 11, the wrapping station is shown ascomprising a turn table, lower in speed that the first wrapper.

At the output unit 22, an arrangement of conveyors moves the palletsaway where a forklift takes the loads. All the movements on theconveyors are automated by a PLC and require no manpower.

Determination of a volume for a first bloc at the dosing and feedingunit 12 is done concurrently with compaction of a second bloc at thefilling and compaction unit 14, stabilization of a third bloc at thestabilization unit 16, measuring of a fourth bloc at the weighing andheight measuring unit 18, and wrapping of a fifth bloc at the wrappingunit 20.

Sphagnum peat moss optionally in admixture with mineral or organicaggregates, having a water-content ranging from about 25 to about 50weight % and a density ranging from about 0.05 to about 0.15 gm/cc ondry basis, is used as feedstock. If the water-content is too low, i.e.,less than 25 weight %, it may be adjusted by adding water by means ofwater sprays for example. If, on the other hand, the water-content ofthe peat moss is too high, i.e., higher than 50 weight %, thecompactions modes need be adjusted to provide a desired density bloc.

As shown in FIG. 12, in a method according to an embodiment of an aspectof the present invention, after determining an amount of peat mosscorresponding to a target bloc (step A), the determined amount is feedto a compaction box (step B) for compaction into a compacted blocsupported by a pallet (step C). The formed bloc is quickly stabilized(step D) and measured (step E), then finally wrapped (step F).

In step A, a volume of peat moss is automatically determined accordingto a target peat moss bloc. Sample amounts of peat moss are collected asa reference for calculating the volume in the bloc.

In step C, according to a first mode, typically for high quality peatmoss, for example peat moss with a water-content ranging from about 25to about 50 weight %, high fiber content, recently cropped etc. . . . ,the peat moss is compressed once fed within the compaction box by apiston and cylinder arrangement. According to a second mode, the peatmoss is twice compressed once fed within the compaction box. Accordingto a third mode, typically in case of poorer quality peat moss or forproviding higher quality blocs for example, a first portion of theamount determined by the doser, for example 60%, is first fed within thecompaction box, first compressed, then the remaining portion of theamount determined by the doser, for example 40% is fed within thecompaction box and compressed on top of the first amount.

The compaction time in step C, between 2 and 30 s, is reduced by abouthalf, compared to conventional methods, by provision of the stabilizingstep D.

The present method allows forming up to 32 palletized blocs per hour,i.e. a cycle time between about 2 and 3 minutes.

The obtained palletized peat moss comprises a body of compressed peatmoss upstanding from a pallet and wrapped with a plastic film, theplastic film retaining the peat moss in compressed form on the pallet.Typically, the palletized peat moss has a rectangular cross-section witha width of about 1.0 meter and a length of 1.2 meters, the heightranging from about 2.0 to about 2.5 meters. The volume of compressedpeat moss retained on the pallet generally ranges from about 6 cubicmeters.

Although the present invention has been described hereinabove by way ofembodiments thereof, it may be modified, without departing from thenature and teachings of the subject invention as recited hereinbelow.

1. A system for palletizing peat moss in bulk form, comprising: a dosingand feeding unit; a filling and compaction unit, receiving an amount ofpeat moss determined by said dosing and feeding unit, and compressingeach determined amount of peat moss into a compressed bloc of peat mosson a pallet; a stabilization unit, receiving, from said filling andcompaction unit, pallets, each pallet supporting a compressed bloc ofpeat moss, and wrapping the compressed bloc for stabilization thereof; aweighing and height measuring unit, measuring each compressed blocreceived from said stabilization unit; and a wrapping unit, finallywrapping each measured compressed bloc.
 2. The system of claim 1,wherein said dosing and feeding unit comprises at least one feedingline, each line comprising a doser.
 3. The system of claim 1, whereinsaid dosing and feeding unit comprises a conveyor feeding peat moss andan equalizer automatically selecting amounts of peat moss to be conveyedto said filling and compaction unit.
 4. The system of claim 1, whereinsaid dosing and feeding unit comprises a conveyor feeding peat moss, anequalizer automatically selecting amounts of peat moss to be conveyed tosaid filling and compaction unit, and a sampler collecting referencesamples.
 5. The system of claim 1, wherein said filling and compactionunit comprises a compaction box, said compaction box comprising a toppart and a bottom part, said bottom part being mobile and adapted tomove away from the top part after compression of the determined amountof peat moss into a compressed bloc to deliver a pallet supporting thecompressed bloc of peat moss from said filling and compaction unit tosaid stabilization unit and return to said filling and compaction unitand reunite with said top part for compression of a next determinedamount of peat moss.
 6. The system of claim 5, wherein said top andbottom parts are sealed together by a mobile flange during compaction,said mobile flange being adapted to disengage the two parts to allow thebottom part to move away from the top part.
 7. The system of claim 1,wherein said filling and compaction unit comprises a pallet manipulatorfeeding the filling and compaction unit with pallets for receiving loadsof peat moss as determined by said dosing and feeding unit.
 8. Thesystem of claim 5, wherein said filling and compaction unit comprises apallet manipulator positioned at the back of the compaction box, saidpallet manipulator depositing one pallet at a time at the back of thecompaction box, and, when the bottom part is ready to receive a load ofpeat moss as determined by said dosing and feeding unit, letting thepallet slide inside the bottom part for receiving the determined amountof peat moss.
 9. The system of claim 1, wherein said filling andcompaction unit comprises a piston and cylinder arrangement controllinga compaction ratio and a height of the compressed bloc of peat moss. 10.The system of claim 5, wherein said compaction box comprises taperedbores on walls thereof as air vents.
 11. The system of claim 5, whereinsaid compaction box comprises inner round corners.
 12. The system ofclaim 1, wherein said stabilization unit comprises a stationary rotaryarm stretch wrapper.
 13. The system of claim 1, wherein saidstabilization unit comprises a top platen, adapted to move to contactthe top surface of the bloc upon arrival from the filling and compactionunit.
 14. The system of claim 1, wherein said weighing and heightmeasuring unit comprises a scale and a linear resistance.
 15. The systemof claim 1, wherein said wrapping unit comprises a turn table.
 16. Amethod for palletizing peat moss in bulk form, comprising: a)determining an amount of peat moss corresponding to a target bloc; b)feeding the determined amount to a compaction box and compacting into acompacted bloc supported by a pallet; c) stabilizing the compacted bloc;d) measuring the compacted bloc; and e) wrapping the pallet with thecompacted bloc thereon.
 17. The method of claim 16, wherein said step a)comprises automatically determining a volume of peat moss according to atarget peat moss bloc.
 18. The method of claim 16, wherein said step a)comprises automatically determining a volume of peat moss according to atarget peat moss bloc and collecting a sample amount of peat moss as areference for calculating a volume in a bloc in said step d).
 19. Themethod of claim 16, wherein said step b) comprises feeding the amount ofpeat moss determined in step a) in the compaction box, compressing thepeat moss on a pellet inserted in the compaction box, and conveying thecompacted bloc on the pallet to a stabilization unit.
 20. The method ofclaim 16, wherein said step b) comprises feeding the determined amountof peat moss compressing the determined amount of peat moss once. 21.The method of claim 16, wherein said step b) feeding a first portion ofthe determined amount of peat moss, compressing the first amount,feeding a remaining portion of the determined amount of peat moss, andcompressing.
 22. The method of claim 16, wherein said step b) comprisesfeeding the determined amount of peat moss compressing the determinedamount of peat moss twice.
 23. The method of claim 16, wherein said stepb) comprises inserting one pallet at a time in the compaction box forreceiving a next load of peat moss.
 24. The method of claim 16, whereinsaid step c) comprises wrapping a first layer of film about thecompressed bloc.
 25. The method of claim 16, wherein said step d)comprises measuring the height and the weight of the compacted bloc.